Process for partial oxidation of hydrocarbons and the like



Oct. 30, 1934.

s. P. BURKE I PROCESS FOR PARTIAL OXIDATION OF HYDROCARBONS AND THE LIKE Filed June 11 0 0mm mint, 1.5 5 9v I new oov man can mmn can 2n 03 mom own Rm 03 n w. my.

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PROCESS FOR PARTIAL OXIDATION OF HYDROCARBONS AND THE LIKE Filed June 11 1950 .3 Sheet sSheet 2 MOWWUMLZQU avwentoz STEPHEN R BURKE @231 his alien t2 l mwWZmOZO Oct. 30, 1934. s BURKE 1,978,621

PROCESS FOR PARTIAL OXIDATION OF HYDROCARBONS AND THE LIKE Filed June 11, 1930' SSheets-Sheet s Smvcnfoz STEPHEN P. BURKE.

Patented Oct. 30, 1934 UNITED STATES PATENT OFFICE PROCESS FOR PARTIAL OXIDATION OF HYDROCARBONS AND THE LIKE Application June 11, 1930, Serial No. 460,319

22 Claims.

The present invention relates to the production of valuable intermediate partial oxidation products of gaseous or vaporized carbonaceous substances such as hydrmarbons, mixtures of these with hydrogen and carbon monoxide such as are produced in coke oven plants, and similar mixtures. It is of particular utility in connection with the homogeneous oxidation of hydrocarbons of the methane series for the production of aldel0 hydes and alcohols.

Many processes for the partial oxidation of hydrocarbon and the like are well-known, in which the reacting materials in the gaseous state are premixed and passed under atmospheric or super- .15 atmospheric pressure through an elongated reaction chamber immersed in a constant temperature heating bath. vThe reaction products are led away, and are subsequently treated to recover the normally liquid components thereof by suitable condensation and absorption under approriate conditions. In many instances the reac--' tion chamber contains certain catalysts adapted to facilitate the desired reactions and to retard other reactions tending to the production of complete oxidation products.

In these prior processes in which reaction tubes of uniform bore are employed, many difficulties are encountered in the proper control of the reactions occurring therein. Especially is this true where superatmospheric pressures are employed, so that as the gaseous mixture is heated to the reaction temperature, considerable fluctuations of pressure occur in the system due to the necessity for the employment of a relatively long reaction tube and to the tendency for the reaction to successively propagate backward and forward in the tube. Under certain conditions these pressure fluctuations may become so large as to prevent the proper control of the conditions in the 4 0 system. As the percentage of oxygen present in the gas mixture is increased, these pressure fluctuations become more serious; and it has been found practically impossible to obtain satisfactory results employing oxygen concentrations above 14% when using a uniform bore tube. Furthermore at the higher oxygen concentrations the formation of carbon taking place frequently causes blocking of these reaction tubes.

Amon the more important objects of the present invention are to provide in an improved manner for controlling the temperature of partial oxidation reactions and for confining the reaction to a definite. relatively-small zone in the system; to provide in an improved manner for preventing substantial pressure fluctuations in. a

system for the partial oxidation of hydrocarbons and the like; to provide a novel method for the rapid cooling of the products of such reaction to insure their preservation; to provide for so controlling these partial oxidation reactions as to assure a smoothly-progressing, uniform reaction irrespective of appreciable variations in the temperature of the heating bath surrounding the reaction chamber; and to provide for the partial oxidation of hydrocarbons such as methane at temperatures substantially below those normally suitable for the purpose and at which temperatures substantially no thermal decomposition of the hydrocarbons or products of reaction would occur.

The present invention is based in part on the discovery that in the processing of gas mixtures of the character mentioned above,the temperature at which the partial oxidation reaction is initiated is lowered as the diameter of the reaction tube is increased, where the total rate of flow of the gas mixture remains constant. This may be explained as due to the inhibitory influence of the wall surface of the tubes which suppresses the homogeneous reaction, (which is evi- 8d dently of the chain type,) by which the desired partial oxidation products are normally produced; or one may regard the phenomenon as being due to the difference in rate of heat transfer using tubes of varying diameter.

It has been found possible so to select the diameter and length of tubing conducting the highly-heated gas mixture to the reaction chamber that all reaction is entirely suppressed during its passage therethrough, although the gas is at a suitable temperature to initiate and support the desired partial oxidation reaction when the gas mixture subsequently flows into a short reaction chamber of suitably-increased cross section and having a larger ratio of volume to heattransferring wall surface than the said tubing. The reaction chamber may be immersed in a heating bath maintained at the same temperature as the gas entering therein, or it may be maintained at a substantially lower temperature for cooling the reaction chamber, as will be hereinafter described. The desired reaction is thereby limited to the relatively small volume of the small reaction chamber, and a smooth uniform reaction is obtained, which prevents pressure fluctuations in the system and gives uniformity of results.

In carrying out the invention the hydrocarbon, or a suitable mixture thereof with a hydrogencontaining fluid and/or a carbon oxide-containing fluid are vaporized where necessary, after which they are mixed with air, oxygen, or other oxygen-supplying gas in the usual way. This gas mixture is then passed through small tubes immersed in a constant temperature bath and maintained at the desired reaction temperature for a suitable length of time to permit the necessary heat transfer to the gases flowing through the tubes. The preheated gases then flow into enlarged chambers which may form part of the said tube assembly or may be separate therefrom, in which chambers the velocity of flow is lowered and the desired reaction occurs suddenly. The gaseous reaction products formed then flow from these chambers through small metal tubes substantially of the size of those employed in preheating the gas mixture, which effects an immediate extinguishment of the reaction, due in part to heat transfer from the reacting gases, if such reaction has not been completed already. The reaction gases are then passed through a suitable train of condensers and separators by which the condensible vapors are condensed and are separated from the permanent gases. The latter, including any unreacted hydrocarbons, oxvgen and the like, may be then mixed with fresh quantities of reactants and recycled in the process. Where the reaction is to be carried out under super-atmospheric pressure, it is essential that means be employed for producing in the various nes, the desired pressure, and that an expann valve or pressure relief valve be disposed in the vapor ofita'xe line leading from the reaction chamber either before or after the condensible vapors have been condensed.

"' accompanying drawings which illustrate in preferred embodiments oi the invenis a graphic representation of the relationship between reaction tube diameter and the reaction temperature, involving the principles una l ing the invention;

shows in somewhat diagrammatic manl apparatus assembly adapted for carry- .ng out the invention;

F g. an apparatus assembly illustrating a modification of the invention; and

l g. i is a vertical section of one form of charm ber d r action tube.

has been found that when a gaseous mixture capable of undergoing homogeneous thermal exjelosion (such for example as a mixture of hydrocarbon and oxygen which can be caused to react extremely rapidly and homogeneously to produce organic oxidation products) is led through a tube of uniform diameter which is heated externally, the temperature of the gas in the tube naturally increases as it proceeds through the tube, always tending to approach the temperature of the heating medium. It has been demonstrated beyond reasonable doubt that during the course of this heating a small amount of reaction occurs between the rcactants. Since the reactions referred to are highly'exothermic, a small amount of heat is liberated so that the temperature existing in the gas as it proceeds through the tube is slightly higher than would be the case for the same gases if no reaction occurred. However, the amount of this reaction is so small that the ordinary analytical methods for gases will detect no change in the composition of the gas in the tube. When, however, the gas mixture in the course of its passage through the tube attains a certain temperature, which we may term the critical temperature (To), reaction suddenly occurs and proceeds to completion almost instantaneously. In the case of a mixture of hydrocarbons and oxygen, where hydrocarbons are in considerable excess, the oxygen content of the gas mixture which was unchanged; in the course of passage through the tube up to a temperature just below the critical temperature suddenly completely disappears and is replaced by products of oxidation.

If we employ a liquid bath with a uniform temperature as the heating medium and immerse the heat transferring tube through which the gas must be passed in the bath and slowly raise the temperature of the bath while measuring the oxygen content in the gases issuing from the tube, we find that the oxygen content remains unchanged as the temperature of the bath increases until a certain temperature is reached and then the oxygen disappears entirely. The curve (I) of Fig. l, representing the variation of oxygen content with. bath temperature is quite typical of hundreds of runs of this character that We have carried out. Now, if we replace the previous tube by another tube of exactly the same length but of larger diameter, and pass the same total quan ty of gas mixture of the same initial composition through the larger tube at the same rate as employed in the previous case, and again plot the oxygen content of the issuing gases versus the temperature of the bath, we obtain a curve simi- 105 lar to curve 2 of Fig. l. The phenomenon in both cases is identical except that the use of the larger tube has lowered the temperature to which the bath must be raised in order to cause reaction to occur. If the diameter of the tube is "-19 made still larger, all other conditions remaining as just described, a curve similar to curve 3 is obtained. It will be observed that as the di ameter of the tube increases the temperature to which the heating media must be brought to cause reaction steadily decreases. It! is noteworthy that successive equal increments of tube diameter cause smaller and smaller reductions in the temperature to which the bath must be raised to cause reaction.

Now, it must be obvious that it we employ small diameter tube, of diameter (D1), we may heat the bath to a temperature (Ta) (indicated on the graph) without having any appreciable reaction occur. If we now cause the gas to issue from the tube 1, into the tube III having a diameter D3, reaction immediately ensues, because the bath is at a temperature in excess of that necessary to cause reaction in the tube oi diameter D3. Therefore by building a reaction system composed of heat transferring tubes of small diameter leading into chambers of large diameter and all maintained at a uniform temperature, it is possible, by proper control of the bath temperature, to preheat the reaction mixture in the smaller tubes to a temperature in excess of that required to causereaction in the larger chamber without having any measurable reaction in the smaller tube. It is furthermore a fact that if the gas is caused to issue from the chambers into tubes of small diameter, either equal to or smaller than the inlet tubes, the reaction initiated in the chambers can'in most cases be extinguished. This briefly describes the phenomena which forms the basis of this patent application. It is subject to modification, as will be hereinafter pointed out. For example, it is not necessary that the chamber be at the same temperature as the preheater tubes; where a sumciently large increase of diameter is employed in 150 passing from the preheater tube to the chamber, the chamber can actually be surrounded by a bath at a lower temperature than that surrounding the preheater tubes.

In. the drawings, numeral 10 designates an elongated closed vessel which may have its exterior wall surfaces heat-insulated if desired. The vessel 10 has a conical bottom 12, and is provided with partitions 14, 16 which divide the vessel into chambers 18, 20 and 22.

A plurality of elongated hollow metal tubes 24, which if desired may be made of catalytic material such as nickel, are disposed in parallel longitudinally of the vessel 10, passing through apertures in the partitions l4, 16--the said tubes having their open, lower ends disposed within the chamber 22.

Each tube 24 extends through an aperture in the top of vessel 10, and has its open upper end associated with a collection head 26. A mid-portion of each of the tubes 24 positioned within the chamber 18 is of increased diameter to form an enlarged reaction chamber 28.

For heating a heat-transferring fluid and for circulating the same around the tubes 24 in the chambers 18 and 20,--a heater 30 is provided, having a burner 32 and a heating coil 34, the respective ends of the latter being connected to the upper and lower ends of chamber 20 through the conduits 36, 38, the last mentioned conduit having a pump or the like 40 located therein. A plurality of bafiles 39 may if desired be arranged around the tubes in chamber 20.

A vaporizer 42 is connected with the upper and the lower portions of chamber 18 respectively by conduit 44 having therein pump 46, and by conduit 48. A conduit connects conduits 38 and 48; and conduit 52 connects conduits 36 and 44.

For introducing into the reaction vessel the hy-' drocarbons to be processed, a conduit 60,--connected with a source of hydrocarbons, as for example natural gas,--is in communication with the chamber 22 through the pipe 62, meter 64, compressor 66, pipes 68 and 69, mixing valve '70 and conduit 72.

If desired, the hydrocarbon gas may be pumped from the compressor 66 through an absorber '74 to remove excess liquids present in the gas prior to being sent through the vaporizer,--or the gas may. be pumped by the compressor .direct into conduit 69 and thence to the vaporizer.

A valved air conduit 76, having a meter therein, leads from a source of air or other oxygensupplying gas under pressure such as the tank 78,

-" through the vaporizer 42 and communicates with the mixing valve '70. Check valves '79 and 81 are preferably placed in conduits '71 and '76 adjacent the valve to prevent back flow through these conduits.

The collection head 26 has leading therefrom a vapor conduit 82 containing an expansion valve 84, connecting the former in series with a condenser 86, a receiver 88 and a gas scrubber 90. A vapor line 92 having therein a flow meter 94 leads from the scrubber to a gas stora e tank 96. A conduit 98 having therein a series of high pressure pumps 100, 102, establishes communication between conduit 92 and a compressed-gas storage tank 104. A conduit 106 leads from tank 104 to raw gas conduit 69; and a short valvecontrolled connection 108 permits direct communication of conduit 98 with the conduit 106.

In the operation of the apparatus shown in Fig. 2, the crude hydrocarbon or a mixture containing hydrocarbons such as natural gas is metered from line 60 and after suitable compression is passed through the absorber 74. The purified vapors are then passed through the coil in the vaporizer 42 where any remaining liquid is vaporized, and the vapors are given an initial preheat. Just prior to the point of exit of the vapors from the vaporizer they are mixed with air or other oxygen-supplying gas which may have been preheated if desired to the same temperature. This gas mixture enters chamber 12 and thence flows into and is distributed uniformly within the relatively narrow preheating tubes 24 through which it flows at a predetermined rate, being meanwhile heated to a high temperature oy heat exchange with the heating fluid, such as fused sodium nitrate, or hot oil flowing around the tubes within the fluid circuit comprising the heater 30. The flow of vapors within the tubes 24 and the temperature of the heated fluid surrounding the tubes is so adjusted that the vapors are heated and maintained at a temperature below that at which the partial oxidation reaction is initiated in preheating tubes of the diameter employed, but above the temperature at which the said reaction will be initiated when the hot vapors flow into the larger diameter reaction chambers 28. As the hot vapors enter the latter, the reaction is instantly initiated, and it progresses rapidly. The mixed vapors then flow at once into the upper tube ends of smaller diameter, which cause the reaction at once to beextinguished. The heat generated by the reaction in the chambers 28 is conducted away from the chamber walls by the heat-transferring fluid flowing in the circuit including chamber 18 and the vaporizer 42, in the latter of which it is used to assist in heating indirectly the incoming gas mixture to be reacted. If desired, the said fluid flowing through chamber 18 may be heated by passage through conduits 48, 50, 38, heater 3D and conduits 52 and 44.

The vaporized reaction mixture leaving the upper ends of the tubes 24 passes the expansion valve 84 where the pressure is reduced to substantially atmospheric pressure, and the vapors then pass through a cooler and condenser in which portions of the vapors are condensed and the condensate recovered in a receiver,the uncondensed vapors passing into a vessel containing a scrubbing liquid such as water or glycerine which absorbs or dissolves certain valuable gas? eous partial oxidation products, the fixed gases then passing to gas storage at atmospheric or superatmospheric pressure; or the mixed gases may be immediately recycled under appropriate pressure. Instead of having the expansion valve 84 in the conduit 82, it may be located in the conduit leading from the condenser to the absorber and between the latter and the receiver 88; or it may be placed in the gas conduit 92.

According to the modification of the invention illustrated in Fig. 3, which is adapted especially for processing the higher hydrocarbons including propane, butane and the like, the arrangement of the preheating vessel and tube assembly, is similar to that shown in Fig. 2. In' place of the type of vaporizer shown in Fig. 2, there is provided a heat insulated column still 43 havin the usual dephlegmating column 45 equipped with the perforated metal plates 47. The hydrocarbon to be vaporized enters the mid-portion of the column through the pipe 69; and the gaseous hydrocarbon is withdrawn through the con duit '72 connected to the top of the still. For heating the contents of the still, a heating coil 49 or a jacket 51, or both is provided. If desired, the ends of the heating coil may be connected respectively with the conduits 14 and 48. One large reaction chamber 29 is disposed within chamber 18, into which each of the tubes 24 extends,in place of the individual reaction chambers 28 shown in Fig. 2. A plurality of relatively small tubes 25 extend from the reaction chamber 29 to the collection head 26.

A conduit 82 leads from the collection head 26 through a condenser 86 to a separator chamber 110, having a valve-controlled draw-off line 112 connected with the bottom thereof. A vapor line 114 leads from the top of the separator chamber to a series of scrubbing vessels 115, 118, each having a valved draw-oil line in the bottom. A vapor conduit leading from the top of the scrubber 118 has therein an expansion valve 122, adapted for holding the desired pressure on the system and for permitting escape from the latter of the scrubbed fixed gases consisting mainly of nitrogen, hydrogen and carbon dioxide. A conduit 124 connects a mid-portion of the separator chamber 110 with a tower provided in its upper end with an aperture 132 normally controlled by a gas release valve comprising a valve seat 134 and a metal float 136 adapted to float on the liquid hydrocarbon within the tower and to seat securely against the said valve seat when in its upperrnost position to seal the interior or" the tower 130 from the atmosphere. A conduit 138 leads from the lower part of the tower 130 through a high-pressure pump 1 10, into the pipe line 62.

The operation of ,the apparatus of 3 is Similar in most respects to that of Fig. 2. A controlled pressure is maintained on the fluid hydro carbon mixture within the portion of the circuit comprising the line 69, vaporizer preheater tubes 2%, reaction chamber 29, and the vessels 11c, 116, 118, and 130 by means of pumps 66 and in the form of the invention shown in Figs. 2 and the reaction tube consists of hollow body 21o of cold rolled steel or other suitable ma terial adapted to withstand high pressures and temperatures. The body 210 has a central aperture which is enlarged at one end of the said body to house a shouldered head or member 212 hav ing a constricted bevelled mid-portion 21a adapted to seat against a sloping mid-portion 216 of the inner wall of the body 21o. A threaded gland and pressure-applying member 21"! engages threads in the body 210 and functions to press the head 212 against the sloping mid-portion 216 of the body 210.

A second apertured head 220, having a bevelled end portion 222 and a threaded portion adlacent thereto adapted to engage threads on the inner surface of a sleeve 22% thereon, is adapted to have its bevelled end 222 pressingly engage a sloping internal shoulder within the body 210 by cooperation with a threaded gland nut 226, the latter engaging threads in the aperture in the body at the end thereof opposite that carrying the member 217.

The lower end of the head 212 extends within the apertured body 210 to a point near but removed from a second constricted portion 227, so that an enclosed chamber 228 is formed between the adjacent ends of the heads 212 and 220 and the internal wall of the body 210 included therebetween. The chamber 228 is in communication with tubes 24 through relatively small central apertures 230, 232, in the respective heads, 212 and 220.

argest Instead of empioying steel as the material of construction for the reaction tubes, various other metals and alloys may be used, which may or may not have catalytic properties with respect to the partial oxidation reaction. In this manner, nickel tubes may be utilized.

In carrying out partial oxidation of hydrocarbons in apparatus of the character described above, it invariably occurs that, while it is necessary to raise the heating bath and the gas mixture flowing therethrough to a given minimum temperature (varying with the conditions of operation) in order to initiate the desired reaction, no reaction occurs at such temperature until 'the gas mixture flows into the enlarged reaction chamber at which point the said reaction occurs instantly and all or the major part of the oxygen reacts and is removed from the mixture. As soon as the desired reaction has been started, the entire system including the heating bath may be cooled down from 25 to 160 C. or more depending upon the conditions of the reaction, the gases used, etc, without causing the reaction to cease. This may be described as hysteresis effect, and

it makes possible uninterrupted operation, irre e spective of relatively large fluctuations in the temperature of the heating bath surrounding the reaction chamber and the tubes conveying the gas mixture to the reaction chamber. Furthermore it has been found possible to carry out the reaction at appreciably lower temperatures than would be possible under similar conditions with reaction tubes of uniform diameter. This is espe cially important where gases such as methane which are highly resistant to the partial oxida tion treatment are being processed, so that the temperatures employed need not be in the range of those effective for thermally decomposing the hydrocarbon to form free carbon so as to seriously reduce the yields-oi valuable partial oxidation products obtained.

For the purpose oi illustrating certain embodi ments of the invention the following examples are given; but it is to be understood that they are in no way to be regarded as limiting the scope of the invention beyond that which is set out in the accompanying claims.

A quantity of propane was vaporized and pro heated to a temperature of approximately 1 to C. and thereafter was mixed with air heated to the same temperature in proportions sufficient to give the resultant mixture an oxygen concentration of 6.15%. l'his gas mixture was passed under a pressure of 750 lbs. per square inch through a 51 inch length of Shelby steel tubing of 5 5" inside diameter, during which time it was brought up to a reaction temperature of 339 G. No reaction whatever occurred under these conditions. From this tubing the mixture flowed into a steel reaction chamber of the type described above, having an inside diameter of 3%", and an internal length of at". lhe fluid inlet end of the chamber was cone-shaped as shown A no temperature of reaction of 339 C. was recorded.

The gases issuing from the reaction chamber were found to contain 1% of oxygen in instances where the preheating bath was maintained at a temperature of 339 C. and below; whereas as the temperature of the heating bath was increased to 393 C. this oxygen was increasingly consumed until at the latter temperature all of the oxygen had been entirely consumed. At the higher temperatures there was a tendency for the percentage of unsaturated hydrocarbons in the oifgoing gases to increase, but the percentage of carbon monoxide did not vary materially. The acidity of the drip recovered at the lower temperatures was somewhat higher than that obtained at the higher temperatures,and very satisfactory yields of methanol and aldehydes were recovered at the various points within the temperature range of 291 to 390 C. In a similar run in which the reaction chamber had an internal diameter of 13/64" and an internal length of 26/64", a propane air mixture containing 5.9% of oxygen, maintained at 750 lbs. per square inch pressure,

and flowing at 15.5'cubic feet per hour, showed a temperature of half reaction of 372 C. It was possible to lower the temperature of the preheating bath to 345 C. without extinguishing the reaction in the reaction chamber, although in such instances the off-going gases contained approximately 1.9% of residual oxygen. To effect complete removal of the oxygen a temperature of 395 C. was necessary.

Similar gas mixtures containing other percentages of oxygen than that recorded above give somewhat similar results. The higher the percentage ,of oxygen present in the original gas mixture, the lower was the temperature of half reaction and that of complete reaction. Furthermore, the permissible drop in temperature of the preheating bath below the temperature required for initiating the reaction, and which would still permit maintenance of the reaction, varied directly with the percentage of oxygen in the gas mixture being treated.

The temperature spread or range between that of half-reaction and that of complete reaction decreases as the oxygen-content of the gas mixture increases; and at oxygen percentages of 14% and above, these two values were approximately the same. Oxygen percentages as high as 18% of the gas mixture,-equivalent to mixtures containing propane and 90% air,cou1d be effectively treated in accordance with the present invention without the formation of carbon in the system, and with resultant substantial yields of valuable partial oxidation products including methanol and formaldehyde, although the most satisfactory yields of these products were obtained with oxygen concentrations around 6%.

To illustrate the character of the results obtained when processing an oxidation-resistent gas normally requiring high temperatures for its conversion,-a mixture of methane and air containing 6.4% of oxygen, while under a pressure of 750 lbs. per square inch, was flowed at a rate of approximately cubic feet per hour through a length of Shelby steel tubing having an inside diameter of 3 and was preheated to a temperature of 468 C. This preheated mixture was then flowed into an enlarged reaction chamber of the type described above, whereupon immediate reaction occurred, with the production of substantial quantities of partial oxidation products including methanol and formaldehyde. The reaction was extinguished by immediately passing the offgoing gases through another length of inside diameter steel tubing. These oifgoing gases contained approximately 2% of residual oxygen, for the removal of which it was necessary to go to a temperature of around 525 C. On the other hand, following the initiation of the reaction a 468 C., the temperature of the reaction bath could be reduced to as low as 440 C.

without substantially eiiecting the character of the reaction or the products formed thereby.

The extent to which the temperature of the r:-action bath could be lowered below the temperature of half-reaction (468 0.), without quenching the reaction may be varied by varying the oxygen content of. the gas mixture being processed, other conditions remaining unchanged. Generally the higher the oxygen content of such mixture, the greater the spread between the temperature of half-reaction and that at which reaction is extinguished within the reaction cham ber.

Reference has been heretofore made in this case to the temperature of half-reaction, by which is meant the temperature at which half of the oxygen of the initial reaction mixture has been used up. This temperature is recorded because of the fact that it has been found difiicult to accurately measure the temperature at which the reaction is initiated or that at which it is complete, while an accurate measurement of the temperature at which half of the oxygen has been consumed can readily be obtained.

In carrying out the process with the apparatus assembly of Fig. 2, a mixture of hydrocarbons, such as natural gas may be flowed through the preheating coil '71 under the desired pressure induced by the compressor 66, and any condensed liquids are removed in the absorber '74. The natural gas is then mixed in the mixing valve '70 with air which has been preheated to the same temperature while passing through pipe 76. The gas mixture then flows into the small steel tubes 24 in vessel 10 around which tubes is circulated a heating fluid such as a fused salt or the like, and wherein the gas mixture is brought up to the desired reaction temperature. The gas mixture then flows into the reaction chambers 28 which are immersed in the heat-transferring bath in chamber 18, which bath may be maintained at the same temperature or at a lower temperature than that of the heat-transferring fluid in chamber 20. The gaseous products of the reaction then flow through the small tubes 24, header 26 and through the expansion valve 84 where the pressure is reduced substantially to atmospheric pressure. The gases then flow through the condenser 86 where condensible vapors are, condensed and'fiow into the receiving vessel 88. The remaining gases flow into the separator 90 below the level of the liquid such as water therein, which absorbs therefrom the constituents condensible or soluble therein,- the remaining or permanent gases being drawn off through line 92 to gas storage tank 96, or they may be pumped direct by means of the booster pumps 100 and 102 to the pressure storage cylinder 104. These gases containing some unreacted hydrocarbons and, in some instances, small amounts of oxygen may then be recirculated in a second cycle of operation, after being fortified with suitable amounts of natural gas or other hydrocarbons through the line 69. The temperature of the preheating baths may be maintained in part by circulation of the preheating fluid through one or more heaters 30, and in part by the heat of reaction transmitted thereto by the reacting gases through the walls of the reaction vessels 28. Other suitable methods for maintaining the desired bath temperatures will readily suggest themselves and may be employed.

Instead of using a plurality of relatively small reaction chambers in the manner shown in Fig. 2, a single large reaction chamber maybe employed into which the various small tubes conveying the incoming preheated gas mixtures may feed the latter. This arrangement does not permit the effective removal of the heat of reaction of the gas mixture to the same degree as the arrangement shown in Fig. 2. Fig. 3 illustrates the preferred arrangement where propane or other gas which is liquefiable under the conditions of use in the process is to be employed. In the operation of the process when using the apparatus of Fig. 3, the gaseous or vaporized hydrocarbons and air or other oxygen-supplying gas are mixed in the vaporizer and are preheated in the small tubes 24 before entering this single large reaction chamber 29. The off-coming vapors fiow through the collection head and conduit 82 to a condenser, and thence into the separator 110 in which the condensed liquid is permitted to settle and stratify, thus forming a lower aqueous layer containing liquid partial oxidation products, and an upper oily layer composed of unreacted hydrocarbons such as propane that are liquid at the temperatures and pressures maintained in the separators. This latter layer contains some of the aqueous products in suspension therein, and also some of the gaseous reaction products which are soluble in the propane at the pressures used. The aqueous reaction products are withdrawn from the separator and subjected to the usual type of refining process for recovering the aldehydes, alcohols, and other materials therein. The propane is withdrawn either continuously or intermittently through conduit 124 and led to the tower 130. In the latter the dissolved gases are permitted to escape from the hydrocarbons to the atmosphere. The float valve 136 functions to prevent overflow and loss of the liquid hydrocarbon should the latter temporarily flow into the tower 130 at a faster rate than the degassed liquid is pumped therefrom into the line 69 for recycling in the process.

The fixed gases flow from the separator 110 through conduit 11 into the scrubber 116 which contains water or an aqueous solution such as glycerine, where any occluded aqueous partial oxidation products not recovered in the separator are removed therefrom, and may be withdrawn through the valved line in the bottom. The remaining gases then flow through conduit 11'? into the oil scrubber 118 containing an oil such as kerosene, in which oil, any residual propane or other hydrocarbon is absorbed and may be removed therefrom by suitable treatment after withdrawal of the oil through the bottom valved conduit. The residual gases flow from the oil scrubber past the expansion valve 122 to suitable storage, or it may be discharged to the open air. In this modification of the invention, the expansion valve is so placed that a major portion of the heat of reaction is removed from the gases flowing from the reaction chamber prior to the reduction of the pressure to atmospheric pressure.

While in the examples given, hydrocarbons and air have been the respective gases employed, it will be obvious that the process is adapted for the treatment of mixtures of hydrocarbons with chlorinating agents, oxygen, and various other oxygen-supplying gases whereby reactions of the well-known thermal explosion type are initiated. Furthermore it is possible to operate at atmospheric pressure or at various other pressures above or below atmospheric instead of at the pressures specifically mentioned herein. There is a tendency for the methanol content of the gases to increase with increase in pressure, and particularly at pressures above 250 lbs. per square inch.

The invention is well adapted for use in connection with homogeneous catalysts such as the nitrogen oxides, methyl ether, and the like. These may be introduced into the gas stream just before the latter enters the reaction chamber, or at some point within the preheater. In some instances the reaction chamber may be constructed of a particular material having catalytic properties adapted to promote the desired partial oxidation reactions. Furthermore the inner surface of the reaction chamber may be coated with a suitable catalytic material such as nickel. In the latter case this may be done by introducing some of the catalyst into the gas stream before it enters the reaction chamber. For instance, nickel carbonyl may be introduced into the gas mixture and flowed into the reaction chamber While heating the latter at temperatures suitable for decomposing the nickel carbonyl, whereby the walls of the chamber are plated or coated with nickel.

The invention is susceptible to modification within the scope of the appended claims.

I claim;

1. The process of controlling homogeneous gas reactions of the thermal explosion type which comprises preheating to a temperature suitable for producing a gas phase reaction of the thermal explosion type a gaseous mixture comprising ingredients capable of mutually interacting to produce such a reaction, while effecting a heat transfer inhibiting the said reaction, and thereafter flowing the preheated gaseous mixture into areaction chamber while removing both the said reaction-inhibiting influence and the excess heat produced by the ensuing gas phase reaction.

2. The process of producing hydrocarbon partial oxidation reaction products which comprises preheating a mixture containing a gaseous hy- 1 drocarbon and an oxygen-supplying gas to a temperature capable of producing a hydrocarbon oxidation reaction while adjusting the heat in the mixture to suppress the said reaction, and

thereafter flowing the said preheated gas mix- 11 ture into a reaction chamber while removing both the said reaction-inhibiting influence and the excess heat produced by the ensuing partial oxidation reaction.

3. The process of producing valuable oxidation products from hydrocarbons, which comprises passing along within an enclosed space having a relatively high ratio of wall surface to volume. a mixture containing a gaseous hydrocarbon and an oxygen-supplying gas which mixture has been preheated to a temperature at which an oxidation reaction is inhibited due to the high ratio 01 wall surface to volume of the said enclosed space, and then flowing the thus preheated mixture into a reaction chamber having a ratio of wall surface to volume sufliciently less than that ofjthe said enclosed space to remove such inhibiting influence, whereupon the reaction immediately ensues.

4. The process of producing valuable oxidation products from hydrocarbons, which comprises ICC- passing along within an enclosed space having a high ratio of wall surface to volume, a mixture containing a gaseous hydrocarbon and an oxygen-supplying gas which has been preheated to a temperature at which an oxidation reaction is inhibited due to the effect of the wall action, and then flowing the thus preheated mixture into a reaction chamber having a ratio of wall surface to volume sufficiently low to remove such in hibiting influence, whereupon the reaction immediately ensues, and subsequently flowing the resultant vaporous reaction mixture into an enclosed space in which the ratio of wall surface to volume is sufliciently high to extinguish the reaction, and removing the reaction products.

5. The process of producing hydrocarbon partial oxidation products which comprises passing a gaseous mixture containing a hydrocarbonaceous fluid, a free hydrogen-containing gas, and an oxygen-supplying fluid through a heated zone of variable cross-section under conditions of temperature and pressure normally adapted to cause a partial oxidation reaction to occur and inhibiting such partial oxidation reaction by the transfer of heat untila predetermined point in the said heated zone is reached, and thereafter removing both the said reaction inhibiting influence and the excess heat produced by the ensuing reaction.

6. The process of producing hydrocarbon partial oxidation products which comprises heating to a reaction temperature a flowing gaseous mixture containing a hydrocarbon and an oxygensupplying fluid under conditions to cause a partial oxidation reaction to be initiated, thereafter reducing the temperature of the heating medium while maintaining the other conditions uniform, and continuing the oxidation reaction by the utilization of heat developed in the course of the said reaction.

'7. The processof producing liquid partial oxi dation products from hydrocarbons, which comprises flowing a preheated gaseous mixture containing a hydrocarbon and an oxygen-supplying gas through an elongated enclosed space having a mid-portion thereof of increased cross-section, initiating and completing the reaction in the said mid-portion, and subsequently extinguishing the reaction as the ""ultant reaction mixture flows from the said nr '.-portion of the enclosed space.

8. The process as defined in claim '7 in which the gaseous mixture is maintained under superatmospheric pressure during the period in which it is being preheated and while the various components thereof are being reacted.

9. The process of controlling the period of reaction of a vaporized mixture comprising a hydrocarbon and an oxygen-supplying gas, which comprises flowing the mixture at a controlled rate through an elongated tube of relatively small diameter and heating the mixture to a predetermined reaction temperature while suppressing reaction, thereafter flowing the preheated mixture into an enclosed space of relatively large diameter and short length, the ratio of the volume to wall surface of the said enclosed space being greater than the ratio of the volume to wall surface of the said elongated tubewhereby reaction occurs between the components of the gas mixture within the said enclosed space, and immediately cooling the products of reaction by conductingthem into a second tube of suitably small diameter adapted to permit sudden cooling of the vapors and suppression of the said reaction.

10. The process for the preparation of partial oxidation products from vaporized mixtures containing a combustible gas which comprises flowing a mixture of the combustible gas and an oxygensupplying gas along an enclosed path and preheating the said mixture to a reaction temperature while suppressing the said reaction by adjusting the rate of heat transfer, removing the suppressing influence at a selected point in the path of the flowing gas mixture by varying said rate of heat transfer, whereupon a partial oxidation reaction suddenly occurs, and immediately thereafter cooling the products of the said reaction while the vapors containing the reaction products are flowing along the said enclosed path.

11. The process as defined in claim 10 including the steps of circulating a heat-transferring medium at least around the portion of the said enclosed path at which reaction has not yet occurred, and substantially reducing the temperature of the heat-transferring medium following the initiation of the reaction in the said enclosed space while maintaining said reaction.

12. The process of producing liquid partial oxidation products from hydrocarbons which comprises flowing a preheated gaseous mixture containing a hydrocarbon and an oxygen-supplying gas through an elongated enclosed space having a mid-portion thereof of increased cross-section, initiating the reaction in the said mid-portion of the enclosed space, and extinguishing the reaction in the gas mixture as it thereafter leaves the said mid-portion, circulating a heat-transferring fluid around but out of contact with the gas mixture flowing through the said mid-portion of the enclosed space and reducing the temperature of the heat-transferring fluid as soon as the said reaction has been initiated while continuing to maintain the said reaction, and regulating by means of the percentage of oxygen present in the mixture the scope of the temperature spread between that at which the reaction is initiated and the lower temperature at which the heat-transferring fluid is maintained during the reaction.

13. The process of producing liquid partial oxidation products from hydrocarbons, which comprises flowing a preheated gaseous mixture containing a hydrocarbon and an oxygen-supplying fluid under superatmospheric pressure through an elongated space having a mid-portion thereof of increased transverse cross-section, initiating and substantially completing a partial oxidation reaction between the hydrocarbon and fluid in the said mid-portion, and substantially extinguishing the reaction as the resultant reaction mixture flows from the said mid-portion of the enclosed space.

14. The process of producing hydrocarbon partial oxidation products, which comprises the steps of preheating a mixture containing a fluid hydrocarbon andan oxygen-supplying fluid to a reaction temperature while adjusting the rate of heat transfer between the said mixture and heating agency thereby suppressing the said reaction, thereafter flowing the said preheated gas mixture into an enlarged reaction chamber while removing both the said reaction-suppressing influence and the excess heat produced by the ensuing partial oxidation reaction, and maintaining superatmospheric pressure upon the mixture through out the said steps.

146 15. The process as defined in claim 14 in which the said mixture is maintained under a pressure of several hundred pounds per square inch.

16. The process of producing hydrocarbon partial oxidation products, which comprises the steps 15:!

of passing along within an enclosed space having a high ratio of wall surface to volume, a preheated mixture containing a fluid hydrocarbon and an oxygen-supplying fluid, maintained at a temperature at which the oxidation reaction is inhibited due to the said high ratio of wall surface to volume within the said enclosed space, thereupon flowing the preheated mixture into a reaction space having a ratio of wall surface to volume lower than that of the said enclosed space, thereby removing the said inhibiting influence whereupon a partial oxidation reaction immediately ensues, and maintaining the said mixture under superatmospheric pressure throughout the said steps.

17. The process of producing liquid partial oxidation products from hydrocarbons, which comprises flowing a preheated fluid mixture containing a hydrocarbon and an oxygen-supplying gas through an elongated enclosed space having a mid-portion thereof of increased cross section, initiating and completing a partial oxidation reaction in the said mid-portion, subsequently extinguishing the reaction as the resultant reaction mixture flows from the said mid-portion of the enclosed space, removing condensible constituents from the reaction mixture, scrubbing the remaining portion oi the said reaction mixture, and recycling the same for use in the process.

18. The process of producing liquid partial oxidation products from hydrocarbons, which comprises iiowing a heated fluid mixture containing a hydrocarbon and an oxygen-supplying fluid through an elongated space immersed in a heated fluid and having a mid-portion thereof of increased cross-section, quickly initiating and completing a partial oxidation reaction in the said mid-portion, subsequently extinguishing the reaction as the resultant reaction mixture flows from the said mid-portion of the said space, removing condensible constituents from the reactioirmiizture, separating the last-named constituents into an aqueous liquid and an oily liquid,

'and heating and recycling the latter in the process.

19. The process as defined in claim 18, according to which the preheated fluid mixture is maintained under superatmospheric pressure during the said reaction step.

20. The process as defined in claim 18, according to which the fluid mixture is maintained under superatmospheric pressure throughout each step of the process.

21. The process of producing liquid partial oxidation products from hydrocarbons, which comprises flowing a preheated gaseous mixture containing a hydrocarbon and an oxygen-supplying gas through an elongated enclosed space having a mid-portion thereof of increased cross-section while maintaining a superatmospheric pressure upon thcmixture, initiating and completing a partial oxidation reaction in the said mid-portion, subsequently extinguishing the reaction as the resultant reaction mixture flows from the said mid-portion of the enclosed space, separating condensible constituents from the reaction mixture, dividing the condensible constituents into an aqueous portion and an oily portion, recovering the aqueous portion, removing dissolved gases from the said oily portion under superatmos- 10d pheric pressure, and recycling the degassed oily material in the process.

22. The process of producing liquid partial oxidation products from hydrocarbons, which comprises flowing a preheated gaseous mixture contaming a hydrocarbon. and not more than 18 per cent of oxygen under a superatmospheric pressure of not less than 250 pounds per sq. in, through an. elongated enclosed space of small transverse cross-section having a mid-portion lid thereof of increased cross-section, initiating and completing a partial oxidation reaction in the said mid-portion, and substantially extinguishing the reaction as the resultant reaction mixture flows from the said mid-portion of the enclosed space.

STEPHEN P. BURKE. 

